Waterproof case

ABSTRACT

A protective case for an electronic device includes a main housing and a lid. The main housing and lid are removably joined to define an air and water tight volume receiving an electronic device. The electronic device includes a switch. The main housing includes a slot formed therein proximate the switch of the electronic device. A toggle is rotatively positioned within the slot. The toggle includes a C-shaped contact portion and the switch is positioned in the C-shaped contact portion and actuated by rotation of the toggle.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 13/591,944 filed on Aug. 22, 2012 which claims priority toprovisional application No. 61/526,093 filed on Aug. 22, 2011 and isherein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The invention relates to water and air sealed cases for electronicdevices.

BACKGROUND OF THE INVENTION

Waterproof housings for various devices are known in the art. Howeversuch water proof housings are not specifically designed for theactuation of toggles or screens of the enclosed electronic device and toprovide a clear transmission of sound from the interior of the case toan exterior of the case and/or from the exterior to the interior of thecase. There is therefore a need in the art for an air and water tightcase that has an improved sound transmission and allows a user toactuate various portion of the device while positioned within the case.

Various water proof applications use porous membranes that allow air topass through but not water & while this is waterproof, this has itslimitations. Such porous membranes are not reliably waterproof as thepores are easily damaged with abrasion, may leak over time and are notsuitable for a dynamic use where they are subject to ongoing movementsuch as to protect against damage from accidental drops, daily use, oroutdoor use. Also many membranes are made with PTFE (Teflon), which haschemical properties of strong resistance to chemical attack as it isrelatively inert, but at the same time PTFE is very difficult to adheredue to its low surface energy and low ability to bond to othersubstances. The low surface energy or the low “wetability” of PTFE meansthat is difficult to form a strong adhesive bonding, which is the basisof waterproof protection. Both the porosity of the material and itsmaterial properties are limitations in utility for waterproof cases.There is therefore a need in the art for an improved water proof housingthat utilizes air impermeable acoustic membranes.

SUMMARY OF THE INVENTION

In one aspect, there is disclosed a protective case for an electronicdevice that includes a main housing and a lid. The main housing and lidare removably joined to define an air and water tight volume receivingan electronic device. Air trapped within the protective case transfersacoustic energy from a sound source within the case to at least onemembrane wherein the membrane vibrates in response to an air pressuredifferential transmitting sound to an exterior of the case.

In another aspect, there is disclosed a protective case for anelectronic device that includes a main housing and a lid. The mainhousing and lid are removably joined to define an air and water tightvolume receiving an electronic device wherein the main housing memberincludes an inner wall and the lid includes a groove formed thereinreceiving a gasket wherein the gasket is radially compressed between themain housing and the lid to provide a water and air tight seal.

In a further aspect, there is disclosed an air and water impermeablemembrane assembly for a device including a device having a housingincluding a port formed therein. A membrane assembly is attached to thehousing in the region of the port. The membrane assembly includes amembrane being non permeable to air and water. The membrane iscompliantly mounted with respect to the port allowing the membrane tofreely vibrate and the housing being sealed from air and water ingress.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of one embodiment of a protectivecase;

FIG. 2A is a partial perspective view of the lower portion of the casemember;

FIG. 2B is a partial sectional view of the speaker port and TPU;

FIG. 2C is a partial sectional view of the home button port andmembrane;

FIG. 3A is a partial perspective view of the lower portion of the casemember;

FIG. 3B is a partial sectional view of the microphone port and membrane;

FIG. 3C is a partial perspective view of the lower portion of the casemember dealing with the sealing rib of the microphone port in oneembodiment of a protective case;

FIG. 4A is an exploded partial perspective view of the upper portion ofthe case member;

FIG. 4B is an assembled partial perspective view of the upper portion ofthe case member and second speaker port;

FIG. 4C is a partial sectional view of the second speaker port andmembrane,

FIG. 5 is a front view of the case;

FIG. 6A is a partial sectional view of the case member, lid and O-ringjoined where there is no attachment structure;

FIG. 6B is a partial sectional view of the case member, lid and O-ringjoined in a region of the first attachment structure;

FIG. 6C is a partial sectional view of the case member, lid and O-ringjoined in a region of the second attachment structure;

FIG. 6D is a partial perspective view of the second attachmentstructure;

FIG. 7 is a partial sectional view of the case member and a plug;

FIG. 8A is a partial perspective view of the upper portion of the casemember;

FIG. 8B is a partial sectional view of a toggle membrane;

FIG. 8C is a partial sectional view of a toggle membrane;

FIG. 9 is an exploded perspective view of a second embodiment of aprotective case;

FIG. 10 are perspective views of a microphone port and membrane of thesecond embodiment;

FIG. 11 are a sectional view and perspective view of the membraneassembly of the microphone port of FIG. 10;

FIG. 12 is a partial perspective view of the lid and membrane assemblyfor a second microphone port of the second embodiment;

FIG. 13 is a partial perspective view of the lid and membrane assemblyfor a second microphone port of the second embodiment;

FIGS. 14A and 14B are perspective views of the case and attachmentstructures of the second embodiment;

FIG. 15 is a perspective view of a seal of the lid of the secondembodiment;

FIGS. 16A and 16B are perspective and sectional views of the caseincluding the lid and main housing and seal of the second embodiment;

FIG. 17 is a perspective view of the case and plug of the secondembodiment;

FIG. 18 is a perspective and sectional view of the case and a toggle foractuating a device of the second embodiment;

FIG. 19 is a perspective and partial sectional view of the case and atoggle for actuating a device of the second embodiment;

FIG. 20 is a perspective view of the case and a second toggle foractuating a device of the second embodiment;

FIG. 21 is a perspective view of the case including an access port ofthe second embodiment;

FIG. 22 is a perspective view and sectional view of the case includingan access port of the second embodiment;

FIG. 23 is graph of acoustic responses for membranes;

FIG. 24 are perspective views of a case member showing air gaps of thesecond embodiment;

FIG. 25 are perspective views of a case member showing air gaps of thesecond embodiment;

FIG. 26 is a perspective view and sectional view showing a port and thinwalled membrane.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the various figures there are shown various embodiments ofa water proof case 10 that includes water and air tight acousticmembranes. For the purposes of creating a waterproof housing to protectthe contents of the housing, it is desirable to have a housing made withthick solid walls made of a structurally strong water proof materialthat can withstand the external environment that it is exposed to and asfew openings as possible. However for the functions of some electronicdevices, there exists a need to have sections that allow the actuationof the device or to somehow allow input and output to be captured. Forexample, specific functional features of enclosed devices may requiresensory response or input such as to proximal visual, reflective,conductive, magnetic, electromagnetic, vibratory, pressure, or acousticelements in the external environment in order for features to operate orbuttons or switches to actuate functions. The enclosed devices may haveother features that capture input or generate output, such as to captureimages, acoustic environment, signals, or to generate light, sound,vibrations, signals. In some of the features described, a consistentthick wall for a waterproof housing will not allow the device to servethese functional purpose within the housing. Hence, some sections mayrequire specific elements to allow the enclosed device to function andoperate in a waterproof environment. Of all of these functions, one ofthe more challenging elements is the capture and transmission ofacoustics in a waterproof housing as this this is usually achievedthrough the use of thin walled sections often with porous membranes thatallow the transmission of sound through air permeable membranes, howeverat the cost of allowing sound to be captured or transmitted at the costof being less waterproof. The use of porous membranes for waterproofnessmay be unreliable as the size of the pores can be easily expanded orpunctured upon touch, which would render them not waterproof. Thereexists a need to create a solution for capture or acoustic transmissiondoes not compromise waterproofness. In the current state of the art, itis not known which materials are suitable to be used as impermeablemembranes with desired acoustic properties and stability for waterimmersion and for outdoor use. Additionally, acoustic membranes in thepresent application are water proof which is a function of having astrong adhesive to form a strong bond with the adhesive bond strengthand the cohesive strength of the materials indicating the degree ofwaterproofness. However, one would expect that a strong bond is betterand an adhesive that holds the membrane tightly would be better forwaterproofness. However, what is not obvious and a part of thisinvention is that the adhesive in fact must be compliant for dynamic useover a wide range of environmental conditions to allow the membrane tofreely move and displace the air volume contained within the housing. Inaddition, to avoid vibrations from the material of the housing to affectsound transmission into and out of the housing, an air and water tightcompressible seal made of an acoustic dampening material such as foam oran elastomer material may be used to surround microphones and seal itfrom the housing to prevent feedback from other sound sources within thehousing, such as speakers and vibrations of the housing itself. Thecompressible elastomer or foam further enhances the compliance of theway in which a membrane is mounted so that it is not compressed betweentwo stiff materials that inhibit its ability to vibrate or displace theair volume and react to the sound pressure differential created when asound source passes through the air and watertight membrane assembly.

In one aspect, the ability to transmit sound in and out of an air andwater tight housing through the design of the membranes and housingdiffers from that of those known in the art. In order to have anincrease in overall volume and lower frequency sound allowing theacoustic membrane to function properly with less distortion and a morefull bass range for a microphone, it is desirable to create an air tightseal between the microphone port of the electronic device and theacoustic membrane to avoid a reduction of the dB of lower frequencysound that passes through the membrane and increase overall loudness.Furthermore, feedback from other internal sources of sound, includingspeakers and the housing itself, may be isolated such that soundreceived is from an external source only.

In one aspect, a thin waterproof acoustic membrane functions best whenit is mounted closer to the microphone and closer to the internalportion of the housing as its vibration becomes the sound source for themicrophone. A spaced membrane located further from the microphone maylower the volume of sound detected by the microphone and the membranemay need to have a larger dimension or be of a thinner material toachieve the same effect, which is a constraint in developing afunctional waterproof housing to transmit sound for some devices.

In one aspect, where the enclosed electronic device functions serves afunctional purpose of voice communication, there are disclosed materialsthat are suitable to form acoustic membranes that produce a suitablefrequency range for the human voice, primarily from 100 Hz to 3000 Hz.By selecting materials with a suitable Young's modulus and density, themembrane frequency response can be adjusted to a target frequency. Asshown in FIG. 23 the compliantly mounted membranes have a higher outputin decibels than the rigidly mounted membrane.

For a speaker, a large dimension membrane is desirable to vibrate andtransmit sound outward. Such a membrane may be mounted to allow it toflex or vibrate using a compliant mounting or the membrane may have asufficiently large dimension or a sufficiently thin dimension to vibrateand transmit sound outward.

In order to create a waterproof seal, an appropriate adhesive must beselected to create a strong bond taking into account the surface energyof the materials, the surface area for bonding and the compliance of thebond allowing the membrane to vibrate and transmit sound.

Equally important to the selection of the acoustic and waterproofmembrane materials are the boundary conditions selected of how themembrane is mounted as this will also affect the frequency range of themembrane. More compliant, less rigid mounting conditions will result ina lower frequency range. The lowest frequency of resonance of themembrane is limited by key mechanical and material parameters. In acompliantly mounted membrane, the low frequency mode of a membranerigidly bonded to the surrounding housing can be determined toapproximate the frequency response of a diaphragm defined as a freevibrating edge-clamped circular disc. The natural frequency of such adisc is determined by the equation. fmn=αmn/4π×√(E/3ρ(1−ν²))×(h/a²):where αmn is a vibrating modes constant of the diaphragm, h is thethickness of the diaphragm, a is the effective radius of the diaphragm,ρ is the mass density of the diaphragm material, ν is the Poisson'sRatio of the diaphragm material, and E is the Young's Modulus of thediaphragm material. The resonant frequency of the membrane may begoverned by this equation. It will show up in the frequency response asa resonance and there may be other vibration modes at higher frequenciescompared to the lowest mode given by this equation. Thus, in order totransfer energy from the acoustic membrane to the speaker, a low modulusis desirable. Specifically, a flexible membrane with low density isdesirable so that the movement of the membrane is maximized whenimpacted by a sound wave such that the sound wave is then re-produced onthe other side of the membrane. This resonance shows up as a peak in thefrequency response of the speaker with membrane. It is further possibleto tune the membrane frequency to provide additional output from thespeaker-membrane unit. This can be achieved by using soft or compliantfoam to mount the membrane to the housing. In a preferred embodiment,soft foam with a viscoelastic adhesive tape on both sides can be used tomount the membrane to a housing as it creates a strong waterproof bondsuitable for dynamic use. More rigid edge conditions for the membranewill result in a higher frequency response for the membrane. Hence, themode frequency of the membrane is dependent upon the Young's Modulus,density and diameter and thickness of the material.

In one aspect, the membrane material may be selected with Young'sModulus from 300 MPa up to 20 GPa and a density from 500 kg/m3 up to2500 kg/m3. Some examples of such materials include thermoplastic filmsPEN, PI, PET, PBT, PE, PC, PVC, PP, EVA; thermoplastic alloys,themosets, thermoplastic elastomers such as TPE/TPU), rubbers such asbutyl, ethylene propylene, silicone, fluorosilicone, epichlorohydrin,chlorosufonated polyethylene, fluoroelastoemers, perfluoroelastomer,tetrafluoroethylene, tetrafluropropylene, polychloroprene, organic filmssuch as, collagen films or films made of natural products like starch,proteins or synthetic polymers, metallic foils or metallized filmsincluding. Aluminum foil and plastic films with metal deposits, andmultilayer systems composed of laminates of different combinations ofmaterials such as PET with foil laminated together. The size of themembrane and the thickness of the material may also be chosen to achievea specific frequency range. In one aspect, a thinner membrane will lowerthe membrane frequency response and conversely, a thicker membrane willresult in a higher frequency response. A larger membrane will give alower frequency response than a smaller membrane using the samematerial. For the purpose of a small device with small acoustic featuressuch as a telephone, mp3 player, video recorder, camera, headphones, andhearing aid, the thickness of the membrane may ideally vary from 5microns up to 1000 microns depending upon the material. The damping orenergy absorption characteristics of the membrane also need to beconsidered. Higher damping (absorb more energy) materials will have asmoother frequency response and show less sharp peaks or resonances intheir frequency response. This will result in a more natural soundtransmission externally from a speaker.

A microphone usually may include an airtight seal around the microphonein order for the membrane to function optimally, allowing a lowerfrequency response, louder overall volume and greater clarity withbackground noise reduction; however the opposite may be required for aspeaker membrane. If the volume of the air between the device and themembrane is reduced, possibly by sealing the speaker membrane, orreducing the volume of air between the device and the membrane, theability of the membrane to vibrate is impeded so that overall soundtransmission is reduced. A speaker membrane may include a sufficient airgap or air cavity to allow the membrane to vibrate. The transmission ofsound in a speaker is a function of the material properties of themembrane, thinness of the membrane, size of the membrane, compliantmounting of the membrane, and the size of the air cavity as all of thesecreate the effect of allowing a flexible membrane compliantly-mounted tocreate low resistance to respond to air pressure. In particular, formembranes that are not permeable to air or water, it is desirable toutilize the pent up air pressure in the air chamber or case to force themembrane to vibrate so that it acts as an air piston. A compliantlymounted membrane allows it to vibrate, instead of clamping it tightwhich inhibits movement. A compliantly mounted membrane includes aspring-like effect that allows the membrane to vibrate and act as an airpiston responding to changes in air pressure to move the membraneallowing sound to transfer and increases an overall sound level. If someinstances, sound from a sound source such may be redirected within anair and watertight housing so that a sufficiently large sized membraneand sufficiently large sized air cavity is available to vibrate to actas an air piston. In an air and water tight housing, the sound may beredirected through the use of strategic air cavities and air gaps toallow the air pressure to move to another larger area of the housingthat can vibrate and act as the speaker membrane to allow sound waves topropagate to the outside of the housing. The sound can be redirected insuch a way because the housing includes non-permeable air tightmembranes so that there is minimal loss in acoustic energy as there islittle transmission loss of the sound since there are no air vents thatwould reduce the air pressure and reduce the potential vibrationalenergy of the membrane. Sound waves are thus generated on the other sideof the air and water tight membrane to the external environment whichcan then propagate through the external medium, whether air or water. Itis known in the art that the sound impedance of air and water aredifferent which limits the ability for sound to travel from a soundsource in air and to be propagated through water without significanttransmission loss. Hence, there is a need in the art to be able topropagate sound underwater without significant signal attenuation. Anair and water tight housing that employs air chambers and anon-permeable membrane to create an air piston permits sound from asource inside the housing to propagate through an external aqueousenvironment without significant attenuation because the acoustic energywithin the housing is converted to vibrational energy of the membrane sothat sound waves may be generated on the external side of the air andwater tight acoustic membrane in water. These sound waves generatedwithin water experience less acoustic impedance underwater so that soundmay be propagated much further, possibly throughout the entire body of acontained water mass, such as a swimming pool. Hence, an operator of adevice contained within such an air and water tight housing may listento music underwater even if they relatively further away from thehousing.

In addition, in some instances, the membrane may need to be isolatedfrom adjacent structures through the use of dampening materials such asfoam or rubber. This may be required if there is vibrations/feedbackthat bounce off the housing that create interference with the speakerand depends upon the spatial orientation of the features within thehousing, although in general, the larger the volume of air, the lessinterference is created.

Referring to FIGS. 1-8 there is shown a first embodiment of a protectivecase 10 for an electronic device 12. In one aspect the protective case10 includes a main housing 14 and a lid 16. The main housing 14 mayinclude a case member 18. The case member 18 may be formed of variousmaterials to provide a rigid structure for the protective case 10. Inone aspect, the case member 18 may be formed of a clear material such asa clear plastic resin. Various plastic resins including polycarbonatemay be utilized.

The case member 18 may include various slots and access ports 20 formedtherein. The slots and access ports 20 may be used to actuate variousfunctions using buttons or switches and allow sound transmission, aswill be described in more detail below. Additionally, the case member 18may include a window portion 22 formed therein that receives a screenmember 24. The case member 18 may include sealing and locating material26 applied thereon on defined portions of the case member 18, such asabout the slots and access ports 20 to provide location and a sealingfor the electronic device 12 as well as allow access to various togglesof the electronic device as will be described in more detail below. Inone aspect, the sealing and location material 26 may include variousplastic elastomers such as a TPE-TPU material or may be formed of othermaterials.

As referenced above, the case member 18 includes a screen member 24attached thereon about the window portion 22 of the case member 18. Thescreen member 24 may be a separate piece attached using various methodsincluding using an adhesive, welding, molding or otherwise attaching thescreen member 24. Alternatively, the screen member 24 may be formed withthe case member 18 and may have a thickness that is different from otherportions of the case member 18. In one aspect, the screen member 24 maybe formed of a clear material allowing viewing of a display of theelectronic device 12. The screen member 24 may have a thickness thatallows a user to manipulate a touch screen of the electronic device 12through the screen member 24. In one aspect, the screen member 24 may beformed of a polycarbonate material and have a thickness of about 0.1 to0.5 millimeters which will allow a user to manipulate a touch screenwith or without another screen protector applied to the electronicdevice 12.

The case member 18 includes at least one sound chamber 28 formedthereon. The at least one sound chamber 28 may be defined by an area ofthe case member 18 that includes a thinned wall section 30 or wallsection that has a smaller thickness than an adjacent portion of thecase member 18. The thinned wall section 30 defines an air space 32allowing for sound to be transmitted to and from speakers and/ormicrophones of the electronic device 12. In the depicted embodiments ofthe figures, two sound chambers 28 are defined in a lower portion 29 ofthe case member 18 and another sound chamber 28 is defined in an upperportion 31 of the case member 18. It should be realized that variousnumbers of sound chambers may be present.

In one aspect, the case member 18 also includes at least one secondarysound port 32. In the depicted embodiments two secondary sound ports 32are formed in the lower portion 29 of the case member 18. The twosecondary sound ports 32 include a speaker port 33 and a microphone port35. Another two secondary sound ports 32 are formed in the upper portion31 of the case member 18 and include a second speaker port 37 and asecond microphone port 39. The secondary sound ports 32 may be definedby slots 34 formed in the case member 18. The slots 34 may be coveredwith the sealing and location material 26 that was discussed above orhave different structures as will be discussed in more detail below.

In one aspect, the sealing and shock mitigation materials 26 may beapplied as a membrane 27 in the region of the secondary sound ports 32.The structures of the membranes 27 may vary based upon the type ofsecondary sound port 32.

As stated above, the protective case 10 includes a lid 16. The lid 16may be formed of a clear material as specified above with respect to thecase member 18. The clear lid allows for a visual inspection of anO-ring as described in more detail below. The lid 16 includes a planarsurface 50 that terminates at an edge 42. The edge 42 includes theattachment structures 38 that mate with the main housing 14. The lid 16also includes a groove 52 that receives a gasket 54. The gasket 54 maybe an appropriately sized O-ring having a desired shore durometer thatseats with the main housing and lid 16 to provide a water tight seal.The lid 16 may also include a camera transmission portion 36 formedthereon, as described above.

Referring to FIG. 2A-B, the membrane 27 positioned about the speakerport 33 may have a unitary structure positioned over the port 33. Theunitary structure may be in the form of a thin film or sheet of materialthat covers the opening and is attached to the case member 18 internallypreventing the entry of water and air allowing for a clear transmissionof sound. In one aspect, the membrane material may be that as describedabove. It has been found that membrane materials having these propertiesallow for the transmission of sound clearly without degradation of thebass frequencies and prevents feedback and echoes within the case. Themembrane 27 about the speaker port 33 provides an acoustic seal of thespeaker of the device 12 to prevent reverberation and feedback. The casemember 18 may include a grill structure 43 formed therein over theopening to the speaker port 33. The grill structure 43 protects themembrane 27 during assembly and use.

Referring to FIGS. 3A-C, the membrane 27 positioned about the microphoneport 35 of the device may have a first membrane assembly 43 positionedwithin the microphone port 35. The membrane assembly 45 may include amembrane 44 attached to a grill structure 47. The membrane 44 may beformed of the materials described above. In one aspect the grillstructure 47 may be formed of a clear material allowing for use a UVcurable adhesive to attach the membrane assembly 43 to the case member18. The membrane assembly 45 provides a water and air tight seal of themicrophone port 35. The microphone port 35 includes a cone shapedchannel 49 to direct and amplify sound as it travels to a microphone ofthe device 12 within the case 10. The sealing and location material 26positioned within the case member 18 and positioned about the microphoneport 35 continues the cone shaped profile and includes a rib or raisedridge structure 48 that mates with the device isolating the speakerpreventing degradation of the sound transmission. In one aspect aseparate structure may be attached about the speaker port to define torib 48.

Referring to FIGS. 4A-C, the second speaker port 37 may include a grillstructure 51 formed in the case member about the speaker port 37. Thegrill structure 51 protects the membrane 53 from damage during assemblyand use. A foam based adhesive 55 such a double sided tape may beapplied about the second speaker port 35 internally to the case member18. In one aspect the foam adhesive 55 may have a thickness in the rangeof 0.4 millimeters. A membrane 53 is attached to the foam adhesive 55bonding the membrane 53 to the case member 18 providing a water and airtight seal. In one aspect the membrane 53 may have materials propertiesas described above. Another adhesive 57 may be positioned about themembrane 53 such that a raised rib 48 may be attached about the membrane53. The raised rib 48 seals a microphone as described above. Thethickness of the foam adhesive 55 provides a separation of the membrane53 from the case member 18 which in combination with the thickness andmaterial properties of the membrane 53 allow the membrane 53 to freelyvibrate and allow for a clear transmission of sound including in a bassfrequency range. The rib structure 48 directs the sound from the secondspeaker of the device to the membrane 53 and isolates the sound fromother portions of the case member 18 preventing sound transmission tothe microphones of the device positioned within the case 10.

Referring to FIG. 4A-B, the second microphone port 39 may include asimilar membrane assembly as described above with reference to themicrophone port 33. A grill assembly 47 and membrane 57 may be attachedwithin the second speaker port 39. Additionally, the sealing andlocation material 26 positioned within the case member 18 and positionedabout the second microphone port 39 includes a rib or raised ridgestructure 48 that mates with the device isolating the microphonepreventing degradation of the sound transmission.

It should be realized that various numbers of secondary sound ports 32may be present. In one aspect, at least one of a sound chamber 28 or asecondary sound port 32 is present in the case member 18.

The case member 18 may include a camera transmission portion 36 formedthereon. The camera transmission portion 36 may be defined by a thinwalled section. The thinned walled section 30 may provide lessdistortion and alleviate focus issues with the electronic device 12positioned within the volume of the protective case 10. In one aspectthe camera transmission portion may include an additional lens such as awide angle or fish eye lens formed or attached to the cameratransmission portion 36.

Referring to FIGS. 6A-D, the case member 18 and lid 16 may includeattachment structures 38 for joining the main housing 14 with the lid16. In the depicted embodiments the attachment structures 38 may beformed at various positions on the case member 18. Various types ofattachment structures may be utilized. In one aspect, as shown in FIG.6B a first attachment structure 61 may be present in the corners 63 andadjoining sides of the case member 18 and lid 16. The first attachmentstructure 61 includes a rounded edge 59 so that the main housing 14 andlid 16 may be joined and separated repeatedly. As can be seen in thefigure, the O-ring 54 is compressed between the wall 67 of the casemember 18 and the groove 52 formed in the lid 16 which receives theO-ring 54. In one aspect, the O-ring 54 receives a radial compressionbetween the main housing 14 and the lid 16 to provide a water and airtight seal. The radial compression is defined by the load applied to theO-ring 54 from the wall 67 of the main housing 14 and the position ofthe O-ring 54 in the groove of the lid 16.

Referring to FIG. 6C-D, the case 18 and lid may include a secondattachment feature 70 present on the lateral or longer sides 72 of thecase member 18 and lid 16. The second attachment feature 70 includes asecondary structure 74 on the main housing 14 to stabilize the wall 67of the case member 18 so that compression of the O-ring 54 does notapply an outward force on the wall 67 away from the O-ring. The secondattachment feature 70 includes a tab 75 on the main housing 14 that istrapped within a groove 76 on the lid 16 such that the lid 16 and casemember 18 are interlocked. Additionally a bump or protrusion 77 on thelid 16 directs the tab 75 over the O-ring 54 and into the groove 76. Ascan be seen in the figure, the O-ring 54 is compressed between the wall67 of the case member 18 and the groove 52 formed in the lid 16 whichreceives the O-ring 54. In one aspect, the O-ring 54 receives a radialcompression between the main housing 14 and the lid to provide a waterand air tight seal. The radial compression is defined by the loadapplied to the O-ring 54 from the wall 67 of the main housing 14 and theposition of the O-ring 54 in the groove of the lid 16.

The case member 18 may also include a detent 40 formed thereon thatallows a user to separate the main housing and lid 14, 16 after theyhave been joined. In one aspect the detent 40 is sized and positioned toallow a user to access an edge 42 of the lid 16.

The case member 18 may include additional structures that allow a userto operate the electronic device 12 with a water and air tight seal. Thecase member 18 may include a plug 44, best shown in FIG. 7 that isattached to the case member 18. The plug 44 includes an attachmentstructure 80 for mating with the case member 18 and a plug portion 82.The plug portion 82 may include a core 84 that is over-molded to definesealing ribs 86 and a sealing cavity 88 on the exterior surface of theplug 44. The plug core 84 stabilizes the plug 44 so that it consistentlyseals into the headphone jack portion 90 of the case member 18.

Additionally, the case member 18 may include various flexible membranestructures 46 to operate buttons or switches associated with theelectronic device. Additional flexible membranes 46 not shown may bepositioned to operate any number of buttons such as a mute button,volume adjustment button, on/off button or any other type of button. Theflexible membrane structures 46 may have various forms and shapes toactuate the desired toggles of the device. As shown in FIGS. 8A-C aflexible membrane structure 46 may include a mechanical feature 92 toactuate the desired toggle. The flexible membrane structures 46 may beformed of the sealing and location material 26 described above or mayanother material attached to the main housing 14. In one aspect, theflexible membrane structure 46 may be over-molded with the main housing14 to define a home button actuation point 94. The case member 18 asstated above includes a sealing and location material 26 attached to theinterior and exterior walls of the case member 18. Portions of thematerial 26 on the interior of the case member 18 may include raisedstructures or bumps 96 to locate and position the device within the casemember 18, as best seen in FIG. 8A. Additional stabilization structures98 may be formed to stabilize the main housing 14 in an over-mold tool.

The case member 18 may also include an attachment structure 48 forattaching to a lanyard allowing a user to carry the protective case 10.The lanyard attachment structure may be positioned at various positionson the case member 18.

In use, a user may position an electronic device 12, such as a phone andin particular a phone having a touch screen within the case member 18.The lid 16 may then be joined with the main housing 14 using theattachment structures 38 such that the O-ring or gasket 54 is seated inthe groove 52 of the lid 16 and a radial compression is applied to theO-ring 54 sealing the lid 16 and main housing 14 and provides a waterand air tight seal. The user may visually verify that the O-ring 54 isproperly seated as the main housing and lid 14, 16 may be formed of aclear material in an area about the O-ring 54. The user may operate thevarious functions of the electronic device 12 through the use of thevarious flexible membranes 46. Sound may be transmitted through theprotective case 10 using the various sound chambers 28, secondary soundports 32, membranes 27 and thin walled portions 30 described above. Thewater and air tight space within the joined case 10 allows for the cleartransmission of sound. Additionally, cameras associated with theelectronic device are operable and have a clear path for transmission. Atouch screen of the electronic device 12 may be operated through thescreen member 24 of the case member 18.

Referring to FIG. 9 there is shown a second embodiment of a protectiveand waterproof case 110. As with the first embodiment, the protectivecase 110 includes a main housing 114 and a lid 116. The main housing 114may include a case member 118. The case member 118 may be formed ofvarious materials to provide a rigid structure for the protective case110. In one aspect, the case member 118 may be formed of a clearmaterial such as a clear plastic resin. Various plastic resins includingpolycarbonate may be utilized.

The case member 118 may include various slots and access ports 120formed therein. The slots and access ports 120 may be used to actuatevarious functions using buttons or switches and allow soundtransmission, as will be described in more detail below. Additionally,the case member 118 may include a window portion 122 formed therein thatreceives a screen member 124. The case member 118 may include sealingand locating material 126 applied thereon on defined portions of thecase member 118, such as about the slots and access ports 120 to providelocation and a sealing for the electronic device 112 as well as allowaccess to various toggles of the electronic device as will be describedin more detail below. In one aspect, the sealing and location material216 may include various plastic elastomers such as a TPE-TPU material ormay be formed of other materials.

The case member 118 includes a screen member 124 attached thereon aboutthe window portion 122 of the case member 118. The screen member 124 maybe a separate piece attached using various methods including using anadhesive, welding, molding or otherwise attaching the screen member 124.Alternatively, the screen member 124 may be formed with the case member118 and may have a thickness that is different from other portions ofthe case member 118. In one aspect, the screen member 124 may be formedof a clear material allowing viewing of a display of the electronicdevice 112. The screen member 124 may have a thickness that allows auser to manipulate a touch screen of the electronic device 112 throughthe screen member 124 and allow for transmission of sound. In oneaspect, the screen member 124 may extend to an ear piece speakerlocation allowing the screen resonate and allow more acoustic energy tobe transmitted through the screen member 124.

The case member 118 includes at least one sound chamber 128 formedthereon. The at least one sound chamber 128 may be defined by an area ofthe case member 118 that includes a thinned wall section 130 or wallsection that has a smaller thickness than an adjacent portion of thecase member 118. The thinned wall section 130 defines an air space 132allowing for sound to be transmitted to and from speakers and/ormicrophones of the electronic device 112. In the depicted embodiments ofthe figures, two sound chambers 128 are defined in a lower portion 129of the case member 118. It should be realized that various numbers ofsound chambers may be present.

In one aspect, the case member 118 also includes at least one secondarysound port 132. In the depicted embodiments a secondary sound ports 132is formed in the upper portion 131 of the case member 118 and includes amicrophone 135. Additionally, the lid 116 may include a secondmicrophone port 139. The secondary sound ports 132 may be defined byslots 134 formed in the case member 118 or lid 116.

Referring to FIGS. 10-11, the membrane 127 positioned about themicrophone port 135 of the device may have a first membrane assembly 143positioned within the microphone port 135. The membrane assembly 143 mayinclude a membrane 144 of a size and thickness as described above andhaving the desired material properties as described above to allow forthe accurate transmission of sound. In the depicted embodiment, a TPUmembrane 144 is attached to foam sections 145 on both side using anappropriate adhesive such as an appropriate double sided adhesive 147 asdescribed above. The membrane assembly 143 is positioned on an innersurface of the case member 118 in the region of the microphone port 135.The foam sections 145 seal the microphone of the device 112 to improvethe sound quality as described above and also spaces the membrane 144 toallow it to freely vibrate for an accurate transmission of sound asdescribed above. The microphone port 135 includes a cone shaped channel149 to direct and amplify sound as it travels to a microphone of thedevice 112 within the case 110. Additionally, the case member 118 mayinclude a lip or extension 151 from the case member 118 toward aninterior of the case member 118. The lip 151 prevents the device 112positioned within the case 110 from damaging the foam sections 145 suchas from a sideways sheering force that may be applied.

Referring to FIGS. 12-13 the second microphone port 139 may be formed inthe lid 116. The second microphone port 139 may include a membraneassembly 155 that also functions as a camera and flash isolationstructure. The entire membrane assembly 155 may be attached to the lid116 using an appropriate compliant adhesive as described above such as a2 mm thick double sided VHB tape to form a water and air tight seal. Inthe depicted embodiment the lid 116 may include a raised lip 117 tolocate the membrane assembly 155. Another raised lip 119 may be definedabout the second speaker port 139 to receive a gasket 141 to block lightfrom a camera flash from travelling through the lid 116 or case member118.

The membrane assembly 155 may include a membrane 161 positioned betweenfoam sections or rubber sections 163. The membrane 161 is formed of aclear TPU material to allow a flash to operate through the membrane 161and also allow for the transmission of sound. As shown in the figuresthe membrane 161 is positioned in a cutout section 165 of the foamsections 163. An adjacent cutout section 167 is defined to receive acamera from the electronic device 112. The camera is isolated from theflash that passes through the membrane 161 of the second microphone port139. The camera operates through the lid material that is positionedbelow the camera cut out section 167. The foam section cutout 165 forthe membrane 161 also includes a notch 169 formed therein to allowacoustic energy to travel to a microphone of the device 112.

Referring to FIGS. 14A-16B, the case member 118 and lid 116 may includeattachment structures 138 for joining the main housing 114 with the lid116. In the depicted embodiments the attachment structures 138 mayinclude hinge features 170 formed in the case member 118 and lid 116allowing the lid 116 to mate with the case member 118 on one side of thelid 116. On an opposing side latches 172 may be attached that pivot andcontact snap fit features 174 on the case member 118 to secure the lid116 to the case member 118. Additionally secondary snap fit features 176may be formed on the lid 116 to mate with the case member 118 andsecurely attach the lid 116 to the case member 118. As can be seen inthe figures, a seal 178 is positioned in a groove 152 formed about theedge of the lid 116. The seal 178 includes a sealing edge 180 and a dustskirt lip 182 to prevent dust and other debris from the interior of thecase 110. The seal 178 is compressed between the wall 267 of the casemember 118 and the groove 152 formed in the lid 116 which receives theseal 178. In one aspect, the seal 178 receives a radial compressionbetween the main housing 114 and the lid 116 to provide a water and airtight seal. The radial compression is defined by the load applied to theseal 178 from the wall 267 of the main housing 114 and the position ofthe seal 178 in the groove 152 of the lid 116. Additionally the dust lip182 seals a gap between the lid 116 and case member 118. The seal 178may include cut out portions 180 to allow the latches 172 to sit flushin the housing 114 when attached.

The case member 118 may include additional structures that allow a userto operate the electronic device 112 with a water and air tight seal.The case member 118 may include a plug 144, best shown in FIG. 17 thatis attached to the case member 118. The plug 144 includes an attachmentstructure 180 for mating with the case member 118 and a plug portion182. The plug portion 182 may include a threaded core 184 that mateswith the head phone slot formed in the housing 114. An O-ring may bepositioned about the plug 182 to seal as the plug portion 182 is screwedinto the case member 118.

Additionally, the case member 118 may include various toggles 146 tooperate buttons or switches associated with the electronic device 112.In the depicted embodiment of FIGS. 18-19, a first toggle 182 may bepositioned on the upper portion of the case member 118. The toggle 182includes an assembly having an actuator having a c shaped contactportion 184 within the case member and a shaft 186 that extends throughthe slot formed in the case member 118 and is received in a controlbutton 188. The shaft 186 may have O-rings positioned around it to sealthe opening in the case member 118 and provide an air and water tightseal. The button 188 may be rotated to cause the C-shaped contactportion 184 to rotate and actuate a switch on the device 112. Anothertoggle 190, as shown in FIG. 20 may be positioned on the upper side ofthe case member 118. The toggle 190 may include a similar structure adescribed above including the button 118, actuator with contact portion184 and O-ring seal.

Referring to FIGS. 21-22, the case member 118 may include an access port192 formed on the upper portion of the case member 118. The access port192 may be used for charging a device or accessing other parts of thedevice 112. The access port 192 includes a removably hinged door 194attached to the case member 118. The hinged door 194 includes a seal orgasket 196 positioned thereon those mates with the case member 118. Thehinged door 194 includes snap features 198 formed thereon that mate withthe case member 118 to hold the door 194 in place A secondary lock 200slides within a channel in the case member 118 to move in and out ofcontact with the door 194 to latch the door 194 to the case member 118.In one aspect, the door may be removed so that accessory devices may bemated with the case 110. For example various accessories such as batterychargers and other devices may include a seal that mates with the casemember 118 and latches to the case member 118 may be included.

In one aspect, as shown in FIGS. 24-26, the lid 116 and screen 124 mayact as an acoustic membrane 204 to transmit sound out of the case 110.As shown in FIG. 24 the lid 116 is spaced from the device in the case todefine an air space or air gap 205. The sound may be redirected throughthe air cavities and air gaps 205 to allow the air pressure to move toanother larger area of the case 110 that can vibrate and act as thespeaker membrane 204 to allow sound waves to propagate to the outside ofthe case. The sound can be redirected in such a way because the case 110includes non-permeable air tight membranes so that there is minimal lossin acoustic energy as there is little transmission loss of the soundsince there are no air vents that would reduce the air pressure andreduce the potential vibrational energy of the membrane. In oneembodiment, the structure of the lid may be utilized to act as theacoustic membrane 204. In one aspect as shown in FIG. 26 the lid 116 mayinclude a cut out portion 210 that may have a thinner piece of materialcompliantly mounted therein to act as the membrane 204. Various sizedcutouts 210 may be utilized with various sized membranes 204 appliedover the cut out 210. The membrane material may be the same or differentfrom the lid 116. Alternatively the lid 116 may be formed as one pieceand act as the acoustic membrane 204. In such an embodiment the lid 116may have a thickness and size which in combination with the air gap 205allows the lid to resonate and transmit sound.

The screen 124 may also act as an acoustic membrane in combination withan air gap 205 as best shown in FIG. 24. As with the lid 116, the screenmay have a thickness and size in conjunction which in combination withthe air gap 205 allows the screen 124 to resonate and transmit sound

The invention has been described in an illustrative manner. It istherefore to be understood that the terminology used is intended to bein the nature of words of description rather than of limitation. Manymodifications and variations of the invention are possible in light ofthe above description. Thus, within the scope of the appended claims,the invention may be practiced or applied other than as specificallydescribed.

We claim:
 1. A protective case for an electronic device comprising: amain housing; a lid; the main housing and lid removably joined to definean air and water tight volume receiving an electronic device saidelectronic device including a switch; wherein the main housing includesa slot formed therein proximate the switch of the electronic device anda toggle rotatively positioned within the slot, the toggle including aC-shaped contact portion and the switch positioned in the C-shapedcontact portion and actuated by rotation of the toggle.
 2. Theprotective case for an electronic device of claim 1 wherein the C-shapedcontact potion includes a circular body having a C-shaped groove formedin a lower surface.
 3. The protective case for an electronic device ofclaim 1 wherein the C-shaped contact portion is positioned within themain housing, the toggle including a shaft extending from the C-shapedcontact potion and passing through the slot.
 4. The protective case foran electronic device of claim 3 further including an O-ring positionedabout the shaft, the O-ring providing an air and water tight sealrelative to the slot.
 5. The protective case for an electronic device ofclaim 3 wherein the toggle includes a button attached to the shaft on anexterior of the main housing, the button rotatable to actuate thetoggle.
 6. A protective case for an electronic device comprising: a mainhousing; a lid; the main housing and lid removably joined to define anair and water tight volume receiving an electronic device saidelectronic device including a microphone and a camera with flashpositioned thereon; wherein the lid includes a microphone port formedtherein proximate the microphone of the electronic device and a membraneassembly attached to a foam material which is attached to the lid by acompliant adhesive, wherein the foam includes a cutout section havingthe membrane disposed within the cutout section and an adjacent cut outsection to receive the camera from the electronic device, the cameraisolated from the flash that passes through the membrane and wherein thecut out section of the foam includes a notch formed therein to allowacoustic energy to travel to the microphone of the device, the membraneassembly transmitting sound to the microphone port and isolating thecamera and flash.
 7. The protective case of claim 6 wherein the lidincludes a raised lip formed thereon locating the membrane assembly. 8.The protective case of claim 7 wherein the lid has a second raised lipincluding a gasket disposed there about.
 9. The protective case of claim6 wherein the membrane is formed of a clear TPU material allowing aflash to pass through the membrane from the device and transfer acousticsignals across the membrane.